Surgical stapler

ABSTRACT

A surgical stapler device of the so-called pistol grip type includes a stack of staples loaded into a lower cartridge in an orientation similar to a conventional paper stapler. A former rotates and turns a leading staple 90° or normal to its prior orientation in the stack of staples as the former slides between a start position and a first intermediate forward position. The former is further displaced to a second intermediate forward position wherein the staple is moved in its perpendicular orientation within the device to the forming position which in turn moves a lower anvil. The former is further displaceable to a third intermediate forward position wherein the staple is formed around a staple forming surface of the lower anvil. The former moves to the final forward position wherein the former cams the lower anvil downwardly separating the formed staple from the staple forming surface of the lower anvil and an anti-bow button of the former contacts the cross-arm of the leading staple and pushes the cross-arm of the leading staple into abutting engagement with a downwardly depending lip of an upper anvil to set the staple. After the staple has been set, the lower anvil and former return together to the anvil home position. During this return, the staple transport surface of the lower anvil ends its lateral return phase below the leading staple in the cartridge. Further retraction of the former allows the lower anvil to rise, lifting the leading staple from the cartridge level to the forming level. This surgical stapler also includes allowing for a varying mechanical advantage to accommodate the staple advance at a reasonable hand force level and provision for adjusting the amount of tissue which is drawn up or approximated within the perimeter of the formed staple.

This application is a continuation of application Ser. No. 07/197,618,filed May 23, 1988, now U.S. Pat. No. 4,991,763.

BACKGROUND OF THE INVENTION

This invention relates to a device for the closure of incisions at theconclusion of many typical surgical procedures. Such closures caninvolve the rejoining of a wide variety of tissue types and bones, suchas the rib cage, fascia, muscle, skin and fat. Primary objectives ofthese closure procedures are to effect rapid and proper healing with aminimum of discomfort and scarring and to ensure that the wound remainssecurely closed. A related objective is that the closure not interferewith subsequent bandages and change of dressing.

Closure generally involves joining various layers of tissue, each in aspecial and correct manner. For instance, in abdominal surgery, thesevered peritoneum layer must be joined, followed by the layers ofmuscle, fascia, fat and skin. Additionally, retention sutures which passthrough all layers may be used or required as insurance that the closurewill not open. To accomplish these sutured closures typical materialsinclude silk, gut in a wide variety of synthetics including Dacron ®,Teflon ®, and various new disposable materials. Depending upon thestrength required, the material may be monofilament or braided and thecaliber may be varied. Also, there are metal sutures which are usuallymade from non-reactive stainless steel. Each material hascharacteristics which make its use appropriate for a specific purpose.

In all these techniques an important consideration is scar formation,the manner in which the human body reacts to suture materials whichbehave, for the most part, as foreign bodies and cause the body'sdefense mechanisms to seal them off with connective tissue. When thebody's reaction is greater, more scar tissue will be formed.

Obviously, sutures cannot be passed without a delivery system which forthese sutures consists of a large assortment of needles. Each type ofneedle is designed to provide a particular function, such as ease ofhandling, ease of passage, ease of release, minimal trauma, etc. Thesurgeon will generally either thread a needle or use pre-threadedsuture-needle combinations in secondary instruments such as sutureholders.

Wound closure is thus a major concern among surgeons and among theprimary objectives of wound closure are: (a) to minimize time requiredto close, (b) to reduce surgeon fatigue and patient anesthesia time, (c)to reduce tissue trauma and accelerate wound healing, (d) to minimizeblood loss, (e) to achieve optimum cosmetic results, and (f) to controland reduce overall costs.

These objectives have led to the development of a relatively new methodof closure, namely, joining adjacent tissue with metal staples deliveredand secured by a staple gun. These metal staples which have partiallyreplaced traditional suture techniques, have become popular for bothexternal and internal closures, including joining cut ends of bloodvessels, hollow organs and various layers of tissue within the body.Dozens of stapling devices for surgery have been developed by Americansand others, especially workers in the Soviet Union.

One aspect of virtually all of these known stapling devices is thecharacteristic way in which they function and the use of bendable butnonresilient metal staples. Force is applied to change the initiallyopen, generally U-shaped configuration of each metal staple to a final,closed configuration, so that the staple will hold two adjacent edges oftissue together. The staple devices are held and operated by thesurgeon's hand, with force applied either manually by the surgeon or bya power-assisted manual force incorporated into the stapler. The forcerequired to bend or crush the ends of the nonelastic metal staples issubstantial, and is typically applied by a driver which drives eachstaple into position and then forcibly bends the legs of the staple.Once placed, the staples cannot be removed without the use of a separatedevice which forcibly returns the staple to its generally openconfiguration, so that removal is possible without tearing the tissue.

Applicant has previously invented a surgical stapler which utilizes aunique delivery system which provides a mode of increased control andincludes provision for turning the staple generally normal to the planeof a stack of staples which are stacked as in a conventional paperstapler, to provide a more efficient and space-saving surgical stapler.The subject matter of such a stapler is disclosed in U.S. Pat. No.4,691,853 issued Sept. 8, 1987. Practical experience with a workingmodel of the invention described in U.S. Pat. No. 4,691,853 has led toseveral improvements described herein which will be perceived asadvantages by the intended users, i.e. surgical personnel.

The improvements include advancing the staple within the case so thatthe rotation occurs within the housing, setting the staple at the end ofthe forward stroke, releasing the staple on the return stroke, provisionfor a varying mechanical advantage to accommodate the staple advance ata reasonable hand force level, and provision for adjusting the amount oftissue which is drawn up or approximated within the perimeter of theformed staple. This application, however, retains the original featuresin U.S. Pat. No. 4,691,853 of rotating the staple and stripping thelower anvil on the forward stroke using the surface of the former torestrain the staple.

OBJECTS OF THE INVENTION

It is a general object of this invention to provide a new and improvedsurgical stapler.

It is also an object of this invention to provide a surgical staplerwhich utilizes a unique delivery system which provides a mode ofincreased control and includes provision for turning the staplegenerally normal to the plane of the stack of staples to provide a moreefficient and space-saving surgical stapler.

It is another object of this invention to provide a surgical staplerwhich achieves a reduction in overall size and weight of the stapler inorder to provide a more exacting control for the surgeon, especially, indifficult-to-reach areas.

It is a further object of this invention to provide a surgical staplerwhich reduces the amount of manual force and motion applied to thedevice when it is at the site or delivery point of the staple so that itcan be readily used by the surgeon without causing movement.

It is still a further object of this invention to provide a surgicalstapler which advances the staple under a stabilizing compressive forceafter it has been rotated to position it at a significant distance fromthe staple magazine to allow the tip of the stapler to be angled toapproximately 45° to the surface to be stapled.

It is still a further object of this invention to provide a surgicalstapler which advances the staple after it has been rotated to aposition at a sufficient distance from the staple magazine to allow thestaple points to be contained within the case or housing while thestaple is being rotated.

It is a still further object of this invention to provide a surgicalstapler which releases the stapler on the return stroke of the formerand as such permits the user to pull the wound edges taught for forcepstissue approximation after the staple is fully inserted but before thetrigger is completely released.

It is a further object of this invention to provide a surgical staplerwhich strips the anvil from the staple on the forward stroke.

It is still a further object of this invention to provide a surgicalstapler wherein the staple is set at the end of the forward stroke withthe final stage of staple formation flattening the top of the staplecross-arm, and as a result thereof, reducing elastic springback of thestaple and thus maintaining better control of the point gap.

It is another object of this invention to provide a surgical staplerhaving a preview latch which locks the stapling device against theaction of the return springs and allows the user to comfortably positionthe staple points which in turn contributes to accurate stapleplacement.

It is a further object of this invention to provide a surgical staplerhaving a variable ratio trigger which transforms the variable or varyingformer force requirements into a more constant trigger force requirementand makes it possible to accommodate a relatively long trigger stroke.

It is yet a further object of this invention to provide a surgicalstapler having a variable tissue shield which determines the volume oftissue which is finally drawn into the perimeter of the closed staple.

The present invention is directed towards solving these problems andprovides a workable and economical solution to them. The new inventiondisclosed and claimed in subsequent sections of this application isfundamentally different from all known prior art stapling systems anddevices.

SUMMARY OF THE INVENTION

The present invention is a hand-held and hand-operated multistagesurgical instrument that carries a plurality of staples, preferably in acartridge, and delivers and closes one staple at a time in the adjacentedges of an incision being closed or adjacent tissue or other substancesbeing joined. This device is operated by squeezing a trigger a selecteddistance toward or into the case, and subsequently, releasing thetrigger to automatically return to its normal position.

One end of a first or lower anvil is fixed to the cartridge retainingthe stack of staples. The lower anvil includes a base having a camfollower surface projecting upwardly therefrom, a staple stack retainersurface extending upwardly from the end of the base in abutting relationwith the stack of staples preventing horizontal movement of the stack ofstaples. The lower anvil also includes a staple transport surfaceextending generally outwardly from an end of the staple stack retainingsurface, and a staple forming surface extending generally upwardly fromthe end of the staple transport surface.

A second or upper anvil is positioned generally above the first or loweranvil and below the upper surface of the case. The upper anvil includesa lip depending downwardly therefrom which aids in preventing ejectionof the staple when the lower anvil is disengaged from the staple.

A staple former slideably advances within the case and includes a pairof arms extending outwardly therefrom which impinge upon the legs of thesubject staple to turn the staple. In addition, a pair of projectionsextend upwardly therefrom and engage with the cross-arm of the staple toform the cross-arm during the forming process. Each arm includes a legretaining edge to retain the staple during stripping from the loweranvil after forming. The former also includes a setting button extendingupwardly therefrom which contacts the cross-arm of the staple and pushesthe staple into abutting engagement with the downwardly depending lip ofthe upper anvil while at the same time eliminating undesired bowing ofthe cross-arm. The former further includes a cam extending downwardlytherefrom which engages with the cam follower surface of the lower anvilfor angular displacement of the lower anvil.

The former is displaceable between a start position wherein the legs ofthe staple are generally perpendicular to the plane of the former andgenerally parallel to the plane of the stack of staples and thecross-arm of the staple is reliably retained by the staple transportsurface, and a first intermediate forward position wherein the legs ofthe former impinge upon the legs of the staple forcing the staple torotate generally perpendicular to the plane of the stack of staples. Theformer is then moved to a second intermediate forward position wherein apair of projections extending upwardly of the former move the turnedstaple until the lower anvil rests against the downwardly depending lipof the upper anvil or until the lower anvil forward motion isinterrupted by the lower anvil abutting a forward stop. Subsequentthereto, the former is moved to a third intermediate forward positionwherein the projections of the former engage the cross-arm of the stapleand form the staple around the staple former surface of the lower anvilinto a closed gripping configuration. In order to complete the forwardstroke of the former, the former is moved to a final forward positionwherein the former is advanced forwardly and the cam of the formerengages the cam follower surface of the lower anvil cantileveringdownwardly the free end of the lower anvil thereby disengaging thestaple from the lower anvil, however, the staple is prevented fromdisengaging through the staple discharge area by the upper anvil. Inaddition, since the width of the upper anvil is slightly less than thewidth of the lower anvil, the staple does not bind onto the upper anvilallowing the staple to slide off the upper anvil when the formerretracts. In this final forward position, a setting button extendingupwardly from the former contacts the staple and pushes the staple ontothe lip of the upper anvil. In this position, the final former advanceflattens the bow of the cross-arm of the staple, which process isreferred to as "setting the staple". This helps to maintain the staplepoints in close contact by reducing the elastic aftereffect known as"springback".

After the staple is set, the former cannot advance further. At the endof the forward stroke, the staple is constrained from ejection from thestapler by virtue of the lip of the upper anvil and the leg retentionedges of the former. Since the staple is not disengaged at the end ofthe forward stroke, the surgeon is allowed to manipulate the wound edgesprior to the release of the trigger. Upon release of the trigger, thelower anvil and the former return together to the lower anvil homeposition. During this return, in the flexed position, the stapletransport surface of the anvil is displaced downwardly to therebyreceive the next leading staple from the stack of staples. Furtherretraction of the former allows the lower anvil to be cantileveredupwardly thereby transporting the leading staple into a position forsequential stapling of the tissue.

In accordance with one of the general objects of this invention, it isdesirable to latch the trigger just prior to staple formation. Thispreview latch locks the mechanism against the action of the returnsprings and allows the user to comfortably position the staple points,which are fully visible for insertion. The "preview latch" feature isbased on two elements, namely, a flex arm molded as part of one side ofthe split case housing which includes a tip having a hooked section forhooking or latching the flex arm onto a latched recess in a raised camfeature molded into the trigger. At the trigger retained position, justprior to staple formation, the flexed flex arm springs laterally intothe latch edge recess molded in the trigger cam. At this point, thetrigger may be released and the flex arm hooked on the trigger cam willhold the case and trigger at a constant relative position against theaction of the trigger return spring so that the user may comfortablyposition the staple points.

Since the force requirements of the former are different at varyingstages of the forming process, the present invention includes a"variable ratio trigger". This "variable ratio trigger" not only drivesthe former in a straight line as the trigger rotates, but also providesfor a low mechanical advantage early in the forward stroke and a highmechanical advantage during staple forming and setting at the end of theforward stroke. This variable ratio trigger design includes two pinswhich are molded into each half of the case and are located so as toengage two cam slots molded into the trigger. The trigger motion isdetermined by the shape of these cam slots. By proper design of theshape of the two cam tracks any desired program of rotation of triggerand linear trigger advance may be achieved.

The new stapler as disclosed herein also permits the surgeon to adjustand determine the volume of tissue which is finally drawn into theperimeter of the closed staple. This is known as "variableapproximation". In one preferred embodiment, a tissue shield surroundingthe staple discharge area is secured to the case and is slideablypositioned relative to the staple points so as to adjust the distancebetween the front edge of the tissue shield and the staple points, whichin turn, allows selection of the degree of tissue approximation. Thetissue shield may be adjusted relative- to the staple at the anvilposition of staple formation by various means including, but not limitedto, gears, screws and cams.

In another preferred embodiment to provide tissue approximation, theupper anvil location is varied, and as such, the case acts to shield thetissue varying the degree of tissue approximation. With this method, theupper anvil location is adjusted by the inclined cam technique wherein aslot on the case and a slot on the upper anvil are coupled via a slidebutton. As the button is slid from side to side, the upper anvil iscammed in and out thereby varying the amount of tissue approximation.

The new stapler as disclosed herein has many features which aresignificant and useful when used in the combination described above orin various other combinations. The new invention comprises first, asurgical stapler system wherein the stack of staples is configured in atypical orientation as those of a paper stapler and further includes ameans of transporting, turning and forming the leading staple so thateach staple may be discharged perpendicular to the stack of staples andsuch that the stapler may be used at great tilt-back angles.

The invention further comprises a delivery system, or apparatus tocontain the staples, and to deliver, strip, and load them as requiredwithout having to use a crushing force. In addition, the improvements ofthis invention include advancing the staple so that the rotation occurswithin the housing, setting the staple at the end of the forward stroke,and releasing the staple on the return stroke. Furthermore, thissurgical stapler provides for varying mechanical advantages of theformer to accommodate the staple advance at a reasonable hand forcelevel and also provides a means for adjusting the amount of tissue whichis drawn up or approximated within the perimeter of the formed staple.

Other objects and advantages of the invention will become apparent fromthe following detailed description and from the appended drawings inwhich like numbers have been used to describe like parts of the severalviews.

DESCRIPTION OF THE DRAWINGS

The following detailed description, given by way of example but notintended to limit the invention solely to the specific embodimentdescribed, may best be understood in conjunction with the accompanyingdrawings in which:

FIG. 1 is a front perspective view of one embodiment of the surgicalstapler of this invention;

FIG. 2 is a cross-sectional view of the surgical stapler taken alongline 2--2 of FIG. 1;

FIG. 3 is a partial top plan view of the surgical

stapler taken along line 3--3 of FIG. 2;

FIG. 4 is an exploded view of the case elements of one embodiment of thesurgical stapler of the present invention;

FIG. 5 is a front sectional view of the present invention taken alongline 5--5 of FIG. 2;

FIG. 6 is a front sectional view of the present

invention taken along line 6--6 of FIG. 2;

FIG. 7 is a front sectional view of the present invention taken alongline 7--7 of FIG. 2;

FIG. 8 is a front sectional view of the present invention taken alongline 8--8 of FIG. 2;

FIG. 9 is a front sectional view of the present invention taken alongline 9--9 of FIG. 2;

FIG. 10 is a partial top plan view of the present invention showing thestaple in the turned position;

FIG. 11 is a cross-sectional view of the present invention taken alongline 11--11 of FIG. 10;

FIG. 12 is a partial plan view of the present invention similar to FIG.10 showing the advance of the staple by the former from the cartridgelocation to the upper anvil location;

FIG. 13 is a cross-sectional view of the present invention taken alongline 13--13 of FIG. 12;

FIG. 14 is a partial top plan view of the present invention similar toFIG. 10 showing the staple being formed around the staple formingsurface of the lower anvil;

FIG. 15 is a cross-sectional view of the present invention taken alongline 15--15 of FIG. 14;

FIG. 16 is a partial top plan view of the present invention similar toFIG. 10 showing further advance of the former cams the lower anvildownwardly thereby disengaging the lower anvil from the staple;

FIG. 17 is a cross-sectional view of the present invention taken alongline 17--17 of FIG. 16;

FIG. 18 is a partial top plan view of the present invention similar toFIG. 10 showing a setting button of the former pushing the formed staplein abutting engagement with the upper anvil;

FIG. 19 is a cross-sectional view of the present invention taken alongline 19--19 of FIG. 18;

FIG. 20 is a partial top plan view of the present invention similar toFIG. 10 showing the partial return of the former wherein the lower anvilis capable of receiving the next leading staple from the stack ofstaples;

FIG. 21 is a cross-sectional view of the present invention taken alongline 21--21 of FIG. 20;

FIGS. 22a, 22b, 22c and 22d are charts representing the former force,former spring force, anvil spring force, and anvil travel requirementsof this invention;

FIGS. 23a and b are schematic representations illustrating the staplestack support system of this invention;

FIG. 24 is an enlarged side plan view of the former and upper anvilrestraining the staple from moving after the lower anvil has beenstripped;

FIG. 25a, b, c, and d are schematic representations illustrating variousmethods of providing for the lower anvil return spring force for thisinvention;

FIG. 26 is a front perspective view of one preferred embodiment of thepreview latch of this invention;

FIG. 27 is a top cross-sectional view taken along line 27--27 of FIG.26;

FIG. 28 is a front perspective exploded view of the variable ratiotrigger of this invention;

FIG. 28a is a cross-sectional view of the present invention taken alongline 28a--28a of FIG. 28.

FIG. 29 is a chart depicting variable trigger ratio program of lineartrigger advance versus trigger rotation;

FIGS. 30, 31 and 32 are schematic illustrations of conventional methodsof forming a staple for insertion into tissue;

FIG. 33 is a side elevational view of one embodiment of a tissue shieldfor varying the amount of tissue approximation;

FIGS. 34 and 35 are top elevational views illustrating the use of thetissue shield of FIG. 40 to vary tissue approximation;

FIG. 36 is a front perspective view of the tissue shield opening for thetissue shield of FIG. 35.

FIGS. 37a, b, c and d are schematic representations of various kinematicmechanisms for varying the tissue shield of FIG. 33.

FIGS. 38a-c are top elevational view illustrating the dimensions of atypical surgical staple.

FIGS. 39a and b are side elevational view illustrating another preferredembodiment of this invention to provide tissue approximation; and

FIGS. 40a and b are top elevational views illustrating the tissueapproximation method of FIGS. 29a and b wherein a slide button cams theupper anvil in and out.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

As shown in FIG. 1, a hand-held and hand-operated multistage surgicalstapler 10 delivers and closes one staple at a time to the adjacentedges of an incision being closed or adjacent tissue or other substancesbeing joined. Surgical stapler 10 is formed generally of a vertical case12 having two halves 13a and 13b. The case has trigger opening 14through which a trigger 16 is engageably inserted. Trigger 16 movesbetween a first extended position (shown in FIG. 1) and second retractedposition upon hand pressure being applied on the trigger 16 by thesurgeon. The bottom 19 of trigger 16 angles upwardly. FIG. 1 illustratesthat trigger 16 is pivotable with about 30° of movement.

The case of the stapler of the present invention also includes a barrel20 having a cylindrical portion 22 and an upper cartridge housing 24.Cylindrical portion 22 includes a circumferential depression or cavity26 formed therein, as best shown in FIGS. 3 and 9. Case 12 includes aplurality of tabs 28 extending outwardly therefrom and each tab 28 isprovided with a head 30 depending downwardly therefrom. Cavity 26 isrotatably engaged by heads 30 of tabs 28 permitting rotational detent ofthe barrel 20 in relation to the case 12. Cavity 26 also includes aplurality of undulations 32, as best shown in FIG. 9, which provide acontrollable orientation of the angular position of barrel 20. Thesurgeon may specifically direct a staple to the desired tissue as thebarrel 20 "locks" at an angular orientation with minimum effort whenhead 30 is retained within undulation 32. With this invention, thesurgeon has a free hand and need not restrain the barrel from furtherrotation with his free hand.

Upper cartridge housing 24 of case 12 includes a top face 34 and abottom face or roof 35 and a pair of side faces 36 depending downwardlyfrom the ends of top face 34. Upper cartridge housing 24 terminates in afront face 38 disposed adjacent to the staple discharge area. The frontface 38 also includes an inclined portion 39 preferably with a 30° anglebetween the front face 38 and the bottom of the trigger 16.

As shown in FIGS. 2 and 3, the forward portion of upper housing 24 ofthe case covers a lower cartridge 50, a stack of staples 52, a pusher82, a first or lower anvil 98, a former 114, and a second anvil 150.Lower cartridge 50 of the present invention, as best shown in FIG. 4,permits the stack of staples 52 to be retained and stacked as in aconventional paper stapler which allows for reasonably manufacturingdimensions and saves critical space in a surgical stapler. The stack ofstaples 52 includes a first staple 53 and a last or final staple 56. Therear wall 58 of the lower cartridge 50 is connected to the base plate 60of the case 12.

Lower cartridge 50 includes a first symmetrical U-shaped channel 62 anda second symmetrical U-shaped channel 64. The first and second U-shapedchannels 62 and 64 are connected by a middle web member 66 whichprovides support for channels 62 and 64. Channels 62 and 64 includeouter facing legs 68 and inner facing legs 70 with outer facing legs 68being greater in height than the inner facing legs 70. The legs 72 ofstack of staples 52 are inserted between the outer and inner facing legs68 and 70, respectively, and the cross-arm 74 of staples 52 abut and areretained by the top edge 76 of inner facing legs 70. As best shown inFIG. 5, the points 75 of the staples 52 do not contact the floor 51 oflower cartridge 50. This prevents frictional drag of the staples 52 inrelation to lower cartridge 50 and permits lower cartridge 50 to be madeof plastic or a plastic-like material. The lower cartridge 50 alsoincludes a pair of side flanges 78 extending outwardly from the outerfacing legs 70 for abutting engagement with side faces 36 of uppercartridge 24. The side flanges 78 extend along the entire length ofchannels 68 and 70 with the exception of a centrally located grove 80.

The present invention also includes a pusher 82 having a top face 84,side faces 86, rear face 88, and front face 90. A rod 92 is centrallypositioned through the pusher assembly 82 and has one end connected torear face 88 and its free end connected to base plate 60 of case 12.Pusher 82 is displaceable between rearward and forward positions by apusher spring 94 disposed about rod 92 which is in biasing relationshipwith rear face 88. Front face 90 of pusher 82 includes an upwardlyextending section 96 which abuts and is adjacent to the last or finalstaple 56 of the stack of staples 52 being retained within lowercartridge 50.

Within the surgical stapler assembly 10, a first or lower anvil 98 ispositioned generally below lower cartridge 50, as shown in FIG. 6, andbetween first and second U-shaped channels 68 and 70. Lower anvil 98includes a base 100 having a pair of side arms 102 extending outwardlytherefrom. Side arms 102 are received by and positioned within groove 80of lower cartridge 50. Each rear face 103a and b of side arm 102includes a flange 105a and b extending downwardly therefrom. A staplestack retainer surface 104 extends upwardly from an end of base 100 andretains stack of staples 52 from further movement as a result of theforce being applied to the staples 52 by means of pusher 82. In thestart position of the lower anvil, the staple stack retainer surface 104generally abuts the first staple 53 within the stack 52. A stapletransport surface 106 extends outwardly from staple stack retainersurface 104 and provides a surface for transporting the first staple 53from stack 52 to a position where it can be turned, transported, andformed. A staple forming surface 108 extends upwardly from the stapletransport surface 106 terminating at a free end 110. The staple formingsurface 108 provides a surface wherein the subject or leading staple 54may be formed around the lower anvil 98 into a generally rectangularconfiguration for insertion within the incision or wound 112 (See FIGS.14 and 15).

A second or upper anvil 150 is secured to case 12 and is positionedbelow the upper cartridge housing 24 and generally above the first orlower anvil 98. The upper anvil includes a top surface 150 whichdirectly abuts the bottom face 35 of upper cartridge housing 24, abottom surface 154, side surfaces 156 and a front face 158 from which alip 160 depends downwardly therefrom. The lip 160 aids the formed staplefrom being ejected after staple formation.

The surgical stapler 10 also includes a former 114 positioned withinbarrel 20 of case 12 between upper cartridge 24 and lower cartridge 50.Former 114 includes a top face 116, a bottom face 118, a pair of sidefaces 120 depending downwardly from the lateral edges of top face 116,and terminating in a front face 122. Outer facing legs 68 of lowercartridge 50 engage the bottom face 118 of former 114 retaining former114 within barrel 20. Top face 116 of former 114 has a pair of arms 124extending outwardly therefrom. Arms 124 impinge upon the leading staple54 which is retained by the staple transport surface 106 and a pair ofprojections 126 extending above the plane of former 114, as shown inFIGS. 10 and 11. Arms 124 provide a means to turn leading staple 54 atleast 90°, or normal to the position of the staple in the stack ofstaples 52 in lower cartridge 50, preferably, to ensure maximum clarityin the surgeon's line of vision when placing a staple in position. Frontface 125 of former 114 is chamfered to aid in rotating the leadingstaple 54. It is, of course, recognized that an angle less than 90° maystill be utilized although an angle less than 90° will not be asbeneficial in terms of providing a clear unimpeded sight line to stapleplacement. As a result of the ability to rotate the staples, the presentinvention utilizes a stack of staples which are in a conventional paperstapler orientation to reduce the space of the stapler and provide forreasonable manufacturing dimensions.

As best shown in FIGS. 12 and 13, in the preferred embodiment of thisinvention, the pair of projections 126 of former 114 extend into theplane of leading staple 54 and apply a force to the cross-arm 55 ofstaple 54 to move the leading staple as well as the lower anvil 98 untilthe first anvil 98 contacts the downwardly depending lip 160 of upperanvil 150 or until the lower anvil contacts its abutting forward stop.In this position, just prior to forming, the leading staple is retainedby staple transport surface 106 and staple forming surface 108 of loweranvil 98, as well as the projections 126. Former 114 is subsequentlyadvanced further such that projections 126 force the staple to be formedin a closed gripping configuration about the staple forming surface 108of first anvil 98 within the incision or wound (See FIGS. 14 and 15).

The former further includes a cam 130 inclined upwardly along the sidefaces 120 of former 114. Cam 130 engages a cam follower surface 132 oflower anvil 98 which extends upwardly from the ends of side arms 102 oflower anvil 98 when former 114 advances to bend or cantilever downwardlythe lower anvil. The relationship between cam 130 and cam follower 132is best shown in FIGS. 16 and 17.

An opening 134 is formed between arms 124 of former 114. Opening 134includes side edges 136 depending inwardly from front face 122 of former114 and rear edge 138. The area of arms 124 between projections 126 andeach side edge 136 define a leg retaining surface or edge 140.

As aforementioned, subsequent movement of the former causes the cam 130to engage the cam follower surface 132 thereby cantilevering downwardlythe lower anvil 98. A setting button 141 contacts the cross-arm 55 ofleading staple 52 and moves the cross-arm into abutting engagement withdownwardly depending lip 160 of upper anvil 150. This final formeradvance flattens the bow of the cross-arm of the staple, which processis referred to as "setting the staple". This helps to maintain thestaple points in close contact by reducing the elastic aftereffect knownas "springback".

After the staple is set, the former cannot advance further. At the endof the forward stroke, the staple is retained within the stapler byvirtue of the lip 160 of upper anvil 150 and the leg retaining surfaces140 of former 114. As such, at the end of the forward stroke, the useris still able to manipulate the wound edges prior to the release of thetrigger.

During return, the lower anvil 98 and former 114 return together to thelower anvil home position. The lower anvil remains in its strippedposition flexed downwardly from the plane of former 114. During thisreturn, the staple transport surface 106 of lower anvil 98 ends itslateral return phase below the next leading staple 53 in the lowercartridge 50. Further retraction of former 114 allows the lower anvil 98to rise lifting the leading staple 52 from the lower cartridge level tothe forming level. As such, a stapling operation has been completed.

Bottom face 118 of former 114 tightly abuts the top of the cross-arms ofthe stack of staples 52. Such an arrangement provides for space savingwithin the surgical stapler 10 and also allows leading staple 54 to beinserted within the wound or incision 142 at a greater angle to thetissue to be stapled as the farther the staple is moved upwardly into aposition to be turned, the less tilt-back angle is permitted with theskin surface to ensure proper stapling.

A ball 144 of trigger 16 engages a load button 146 which causes former114 to advance in a straight line motion. A first or main spring 148which is in biasing relation with load button 146 causes trigger 116 andformer 114 to return to their start position. As will be describedherein, since the force requirements of the former are different at thevarying sequence steps of the forming operation, a variable ratiotrigger is also provided herein.

In use, the present invention is operated by squeezing a pivotingtrigger 16 a selected distance towards or into case 12, and subsequentlyreleasing trigger 16 to automatically return to its rest position. Thismotion of trigger 16 activates a multi-stage operation that includes thefollowing steps: (a) turning the staple 54 to an orientation generallynormal to the incision or wound for subsequent closure and ejection ofthe leading staple; (b) transporting the leading staple and the loweranvil a predetermined distance until restrained from further movement bythe downwardly depending lip 160 of upper anvil 150; (c) forming theleading staple 54 around staple forming surface 108 of lower anvil 98into a generally rectangular configuration closing legs of leadingstaple 54 within the incision or wound 112; (d) stripping the loweranvil 98 out of engagement with the cross-arm 55 of leading staple 54;(e) forcing the staple into contact with the downwardly depending lip160 of upper anvil 150 and setting the staple by having setting button141 of former 114 contact the bowed cross-arm of leading staple 54; (f)releasing the staple on a fully controlled basis into the tissue of thewound or incision 112 without having the staple retract with lower anvil98; (g) returning the lower anvil and the former 114 to their homeposition such that the staple transport surface 108 of lower anvil 98ends its lateral return phase below the leading staple in the staplecartridge 50; (h) loading first staple 53 from stack of staples 52 ontothe staple transport surface 106 of lower anvil 98; (i) transportingleading staple 54 into a position where it can be turned generallynormal to the plane of the stack of staples 52; and and (j) turning anew staple as in paragraph (a) above to repeat stapling. Each of thesesteps will be described in detail below.

FIG. 2 illustrates the leading staple 54 in its starting position. Thestack of staples 52 is retained within lower cartridge 50 with legs 72of the staples depending generally downwardly. The cross-arms 74 of thestack of staples 52 are tightly retained by bottom face 118 of former114. The pusher 82 upon the urging of pusher spring 94 exerts a forceupon the stack of staples 52. The stack of staples 52 is restrained fromfurther movement by staple stack retainer surface 104 of lower anvil 98.

As shown in FIG. 2, in its starting position, the leading staple 54 hasits legs 57 depending generally downwardly generally parallel to legs 72of the stack of staples 52. Leading staple 54 is retained within theopening defined by staple transport surface 106 of lower anvil 98 andthe upwardly extending step 71 of lower cartridge 50. In the restposition, cam 130 of former 114 is recessed behind cam follower surface132 of anvil 98 and does not engage cam follower surface 132 asillustrated in FIGS. 2 and 8.

As shown in FIGS. 2, 10 and 11, former 114 is displaceable between astart position, wherein the legs 57 of leading staple 54 are generallyperpendicular to the plane of former 114 and parallel to the plane ofthe stack of staples 52 and cross-arm 55 of leading staple 54 isreliably retained between arms 124 of former 114, staple transportsurface 106 of lower anvil 98, and bottom face 154 of upper anvil 150,and a first intermediate forward position, wherein legs or arms 124 offormer 114 advance forwardly upon actuation of trigger 16 exerting aforce upon load button 146. In the former first intermediate forwardposition, former arms or legs 124 impinge upon legs 57 of leading staple54 so that legs 57 are turned upwardly in a plane generally normal tolegs 72 in the stack of staples 52 and parallel to the plane of former114.

After the loaded staple is turned or rotated, the former moves to asecond intermediate forward position (FIGS. 12 and 13) wherein theprojections 126 engage the cross-arm 55 of leading staple 54 which inturn pushes lower anvil 98 until lower anvil 98 contacts the downwardlydepending lip 160 of upper anvil 150 or flanges 105a and b contactspring support or forward stop 169. After the lower anvil contacts theforward stop the lower anvil ceases to advance with the former 114 aswill be described hereinafter.

FIGS. 14 and 15 illustrate the forming of leading staple 54 within theincision or wound 112. Former 114 advances further forwardly from thesecond intermediate forward position into a third intermediate forwardposition. In this third intermediate forward position projections 126 offormer 114 advance forwardly and apply a force upon cross-arm 55 ofleading staple 54. The staple 54 is formed around staple forming surface108 of the lower anvil 98 into a generally rectangular configurationwherein legs 57 of staple 54 close adjacent one another within theincision or wound 112 (FIG. 15). The leading staple 54 is formed in aplane generally perpendicular to the plane of the stack of staples 52and in a plane generally parallel to the plane of former 114. Asillustrated in FIGS. 14 and 15, the staple in the formed position withinthe incision or wound 112 is retained within the surgical stapler 10 bystaple forming surface 108, staple transport surface 106, and legretaining surface or edge 140 on top face 116 of former 114. Of course,the leading staple 54 will also be retained by the tissue of the woundor incision 112.

During the process of forming the staple, the cross-arm of the staplehas a tendency to bow up. This bowing must be allowed for in thedimensioning of the various former features which have been provided forin the present invention. As is shown in FIGS. 16 and 17, when theformer is moved to a final forward position, the cam 130 of former 114engages the cam follower surface 132 of anvil 114 cantilevering orbending downwardly lower anvil 98 disengaging the leading staple 54 fromstaple forming surface 108 of lower anvil 98 (See FIGS. 18 and 19). Thestaple, however, is prevented from disengaging with the stapler as aresult of its placement with respect to the lip 160 of the upper anvil150 as well as the leg retainer surfaces 140 of the former 114.

Referring now to FIGS. 18 and 19, after the lower anvil has been cammeddown sufficient to unblock the staple, in the final forward position asetting button 141 of former 114 contacts the staple at the formeradvance corresponding to the unblocking of the staple by the loweranvil. This setting button 141 pushes the staple into abuttingengagement with the downwardly depending lip 160 of upper anvil 150.This final former advance flattens the bow of the cross-arm of 55 ofleading staple 54, which process is referred to as "setting the staple".This helps to maintain the staple points in close contact by reducingthe elastic aftereffect known as "springback".

As aforementioned, the staple is formed around the lower anvil andtransfers onto the upper anvil after the lower anvil is cammeddownwardly. The staple is finally set by the former against the upperanvil (see FIGS. 18-19). Since the upper anvil 150 is less wide than thelower anvil, frictional engagement between the staple and the upperanvil is prevented when the lower anvil is stripped from the staple. Italso allows the upper anvil to easily disengage from the staple when theformer retracts. To facilitate the disengagement of the upper anvil andthe staple, the upper anvil is preferably shaped as shown in FIG. 24.The upper anvil has a chamfered edge 162 into which the cross-arm 55 ofthe leading staple abuts. By reducing the engagement e of the upperanvil into the staple to a minimum consistent with good design practiceand by angling the surfaces of the upper anvil, as shown in FIG. 24, theupper anvil may be made to easily disengage from the pinch between thestaple on the one side and the approximated tissue on the other. It isimportant that the staple easily disengage from upper anvil 150 afterthe former retracts to avoid any so called "hang-up" in releasing thestapler from the tissue. In case of such "hang-up", the user is requiredto pull the stapler free, which action is obviously highly undesirable.

After the staple is set, the former cannot advance further. This is theend of the forward stroke. At the end of the forward stroke the stapleis attached to the stapler by virtue of the downwardly depending lip 160of upper anvil 150 and the leg retaining surfaces 140 of the former.This is in contrast to U.S. Pat. No. 4,691,853 where the staple isdisengaged from the stapler at the end of the forward stroke. Thissystem allows the user to manipulate the wound edges prior to release ofthe staple which will be discussed in more detail herein.

As best shown in FIGS. 20 and 21, after the staple has been set, thelower anvil and the former partially return to their home positiontogether. The lower anvil 98 returns to its home position as a result ofthe biasing force of anvil return spring 168 secured to spring support169. During retraction, the lower anvil 98 remains in its strippedcondition in a horizontal plane below the horizontal plane of former 114to be capable of receiving the next leading staple 53 from stack ofstaples 52.

As the lower anvil and former complete the final phase of their returnstroke, the staple transport surface 106 of lower anvil 98 movesdownwardly so that it is at a vertical level generally in the plane ofcross-arm 74 of first staple 53 within stack of staples 52. The firststaple 53 within the stack of staples 52 is urged forwardly to beretained by staple transport surface 106 as a result of force applied bypusher 82 upon stack of staples 52. A built up ramp 71 on lowercartridge 50 aids in lifting the cross arm such that it can be easilyreceived by the staple transport surface 106.

In order to complete one cycle, after the former retracts to a positionrearward of the vertical plane of the staple transport surface 106, thelower anvil 98 is cantilevered or bent upwardly (see FIG. 2)transporting the leading staple 54 upwardly with its legs in a planegenerally parallel to the plane of the stack of staples 52. The leadingstaple 54 is transported upwardly within the cavity defined by stapleforming surface 108 and staple transport surface 106. The leading staple54 is transported upwardly into the start position of the former asshown in FIG. 2 wherein the leading staple is retained within theopening defined by the upwardly extending step 71 of lower cartridge 50and the staple transport surface 106. As such, the cycle is completedand further stapling repeats the above-mentioned cycle.

The force required to move the former varies throughout the cycle. Theformer force, former spring force, anvil spring force, and anvil travelrequirements are shown in FIG. 22(a)-(d), respectively. Each phase ofthe former force requirements of FIG. 22(a) are described in detailbelow.

    ______________________________________                                        PHASE  DESCRIPTION                                                            ______________________________________                                         0-1   Force required to overcome the former return spring                           pre-load.                                                               1-2   Former advance to turn staple.                                          2-3   Force increase to overcome anvil return spring                                pre-load.                                                               3-4   Former advance to advance staple and lower anvil to                           upper anvil location. Both former and anvil return.                           spring forces increase                                                  4-5-6 Staple formed.                                                          6-7-8 Lower anvil stripped.                                                   8a    Setting of staple.                                                      8-9   Former and lower anvil return together.                                 9-10  Lower anvil return spring pre-load unloaded against                           home stop.                                                             10-2-1 Former returns to home position.                                        1-0   Former return spring pre-load unloaded against                                former home stop.                                                      ______________________________________                                    

The present invention also provides a unique support for the staplestack. In the present invention, the staple stack remains stationerywhile the lower anvil and former advance even though the pusher spring94 is applying pressure to the rear of the stack tending to advance thestack forward. Referring now to FIG. 23a, in this invention, the leadingstaple abuts an edge of case 12. This edge holds back the entire stackof staples even though the pusher spring force is urging the staplesforwardly. FIG. 23b illustrates why the stack does not does shinglecausing the stack to collapse. In order for the condition of FIG. 23b tooccur, the spacing between staples would need to increase to a valuegiven by: ρ=d/cos θ where d equals the staple diameter. If the stackshingles, as shown in FIG. 23b, the space occupied by the stack wouldincrease and, consequently, the pusher spring 94 would compress. Thepusher spring 94, therefore, prevents the stack from shingling and itremains stationary as is shown in FIG. 23a. As shown in FIG. 12, theaforementioned rail step 71 also abuttingly retains the cross-arm of thestack of staples.

Another major improvement is the staple advance mechanism within thestapler assembly. The lower anvil 98 is advanced by the former 114 andreturned by a spring. The methods of providing this return spring actionare described below.

In the first method, as shown in FIG. 25a, the staple stack pusherspring 94 bears against a bent up tab 164 of lower anvil 98 at theopposite end of lower anvil 98 from the staple forming surface 108. Thisspring acting on the bent up tab of anvil 98 and the pusher providesboth the stack advance pressure as well as the anvil return springforce.

In the second method (as shown in FIGS. 25b and c), the lower anvil 98is anchored to case 12 by means of a bent up tab 164a, similar to theprevious bent up tab 164 which flexes, sufficient to accommodate thelower anvil 98 motion.

In the third method (see FIG. 25d), the lower anvil 98 is provided witha downwardly extending tab 166 at an end opposite to staple formingsurface 108. A dedicated or anvil return spring 168 is provided inbiasing engagement with downwardly extending tab 166 to provide thereturn action of the lower anvil 98.

In accordance with one of the general objects of the present invention,it is desirable to provide a latch to interrupt the trigger just priorto staple formation. This locks the staple mechanism against the actionof the return springs and allows the user to comfortably position thestaple points, which are fully visible, for insertion. As is shown inFIGS. 26-27, the preview latch 170 includes a flex arm 172 molded aspart of one side of the split case housing 12. This arm is flat and thinin the lateral direction allowing easy flexing. The tip 174 of flex arm172 has a hooked section 176 for hooking or latching onto a latch recess178 in a raised cam feature 180 molded into trigger 16.

In the process of squeezing trigger 16, the flex arm 172, as best shownin FIG. 27, contacts a first camming surface 180 of cam 178. This firstcamming surface 180 guides and flexes the flexed flex arm 172 laterallyinto the latch edge 178 just prior to staple formation. At this point,the trigger may be released and the flex arm hooked on the trigger camwill hold the case and trigger at a constant relative position againstthe action of the trigger return spring. As such, the user maycomfortably position the staple points, which are fully visible, forinsertion.

After the user is satisfied that the staple points are in the properposition, further actuation of trigger 16 causes the flex arm 174 tobecome disengaged from latch edge 179 and be guided by second cammingsurface 182 of cam 178 to return to its home position.

U.S. Pat. No. 4,691,853 describes a stapler with a fixed pivot triggerhaving a relatively constant mechanical advantage through its stroke.The force required, however, in the current improvement varies from alow value early in the forward stroke to a high value during stapleforming and setting at the end of the forward stroke. As such, applicanthas designed a unique "variable ratio trigger" in order to accommodatethe varying force requirements of this stapler.

In a fixed mechanical advantage device, such as a stapler with a fixedpivot trigger, a long stroke is achieved at low mechanical advantage.High mechanical advantage can be achieved only by reducing the stroke.It is, therefore, desirable to have a variable mechanical advantage. Atrigger incorporating a variable mechanical advantage during actuationis referred to as a "variable trigger ratio." With such a feature, thevariable or varying former force requirements are transformed into moreconstant trigger force requirement.

As is shown in FIG. 28, in order to achieve this result, the trigger 16is molded with two cam tracks 184a and respectively, molded into the twohalves 13a and 13b of case 12. The cam tracks are shaped so as to causethe ball 144 which engages load button 146 which drives the former tomove in a straight line as trigger 16 rotates. The relationship betweenthe rotation of the trigger and the advance of the former contact pointscan be varied by design to produce the desired varying mechanicaladvantage.

In use, the trigger motion is determined by the shape of the cam tracks.By proper design of the shape of the two cam tracks, any desired programof rotation of trigger and linear trigger advance may be achieved. Thestaple trigger is actuated by the user's hand. It in turn drives theformer 114 forward to accomplish the forward stroke of the cycle. Theformer requires a certain minimum travel to complete the functions ofrotate, advance, form, strip, and set. The trigger size and travel isconstrained by the requirement that a normal size hand be comfortablyable to grasp it. Furthermore, the force required of the hand must notexceed a certain maximum to avoid discomfort and fatigue.

To make best use of the trigger travel available, it is useful to designthe ratio between the trigger travel and former travel to match the needfor force leverage or mechanical advantage during the cycle. In thiscase, it is lower during the early part of the cycle and greater duringthe later part when the staple is being formed and stripped. The triggeradvance, hence, should move the former rapidly at first with a lowmechanical advantage when the former force requirement is low and slowlyas the staple is being formed when the force requirement is high. Asimple trigger pivoting around a fixed pivot point cannot tailor themechanical advantage to that desire to achieve compromise between thetrigger travel available and former force required. A cam drive inaccordance with this invention can provide the variable ratio actiondesired.

Furthermore, the rotation versus advance program shown in FIG. 29, isdesired where:

(a) full trigger rotation is denoted by θ_(m) ;

(b) full trigger linear advance is denoted by X_(m) ; and

(c) the relationship between rotation and advance is non-linear as shownwhere the advance versus rotation is high at first and lower later inthe stroke.

The inverse of the slope of the curve of FIG. 29 is the mechanicaladvantage.

The use of the cam tracks in the preferred embodiment of this inventionprovides for movement of the former rapidly in a straight line motion atfirst with a low mechanical advantage when the former force requirementis low and slowly as the staple is being formed when the forcerequirement is high.

In the field of surgical staplers, the conventional method of formingthe staple for insertion into tissue is shown in FIGS. 30-32. In theconventional formation process, the staple bends at point A. The staplepoint B follows a circular path of radius a² +b² shown in FIG. 31.Staple formation occurs with the staple located relative to the housingin FIG. 31. In this configuration, the staple points protrude below thelower portion of the housing by an amount "d". That dimension togetherwith the staple geometry and any forceps induced tissue effectsdetermines the level of tissue within the perimeter of the formedstaple. After the staple has been formed, the level of tissue within theclosed staple is denoted by H in FIG. 31. In conventional staplers,these conditions are fixed by design. In the present invention, however,these conditions are controlled or selectable by the surgeon. Theadvantage of being able to select the amount of tissue contained withinthe formed staple is that whereas in conventional staplers the depth ofthe staple insertion is variable according to the force with which thestaple is pressed against the tissue, in this invention, the surgeon mayadjust the stapler to accommodate his own preferred technique. As such,adjusting the instrument to the user is preferable to having to adjustthe user's own surgical techniques.

There is a variety of reasons for the surgeon desiring to control theinserted staple condition. These include accommodating varying degreesof tendency to press the stapler against the skin, the variability ofskin thickness in different areas (e.g. neck versus stomach) and thedesire to avoid crosshatching the skin across the wound gap by thestaple cross-arm.

In conventional staplers, the dimension "d" shown in FIG. 32 is fixed bydesign and determined by the physical relationship of the anvil to thehousing. This design dimension is chosen experimentally to achieve abalance between too little approximation for a small or negative valueof "d" and too great an approximation of tissue for to large a value of"d". There is a value of "d" for which no tissue approximation occurs.This relationship is shown in FIG. 32. The value of "d" denoted "d_(min)" for which no tissue approximation occurs is given by the equation:d_(min) =a² +b² -a. As the surface A shown in FIG. 32 is moved upwardly,the staple points are able to gather in increasing amounts of tissue.The value of "d" in excess of "d_(min) " determines the distance belowthe surface A which the staple points attain in swinging from the fullyopen pre-formed condition of FIG. 32 to the fully closed or formedcondition of FIG. 31.

This invention is advantageous to the conventional stapler in that theselection of "d" is left to the surgeon who may increase or decrease thedistance "d" to suit his technique and existing surgical conditionsduring the wound closure procedure to achieve a more effective endresult.

In one preferred embodiment for a tissue approximation technique asshown in FIGS. 33-36, in order to control the distance "d", the surgicalstapler includes a slidable tissue shield 190 secured to top face 34 ofcase 12. Tissue shield 190 which may be slidably positioned relative tothe staple points so as to adjust the dimension "d" thereby adjustingthe amount of tissue approximation. Tissue shield 190 includes a tissueshield opening 194 (See FIG. 36) which provides for sufficient clearanceto allow staple ejection.

The tissue shield may be adjusted relative to the staple at the anvilposition of staple formation by various means including manyconventional kinematic mechanisms such as gears, screws and cams.Examples of each are shown in FIGS. 37a-d. Each mechanism provides anadjustable link 196a, b, c and d, respectively, which the surgeon usesto position the tissue shield. The motion of the adjustment linkprovides for relatively small position adjustments of the tissue shieldwhich are required. For example, a typical staple is shown in FIGS.38a-c, before and after forming. For this staple, the zero approximationshield position is 0.04 inches below the points. The maximumapproximation shield position is also shown in FIG. 38b at the level ofthe staple cross-arm. The full range of adjustment is thus 0.14 inches.This small adjustment cannot be controlled comfortably without amechanism to amplify it to an adjustment range compatible with surgeon'ssense of adjustment or ability to control motion. In the case of alinear adjustment link, such as shown in FIG. 37d, an adjustment linkmotion of approximately 0.5 inches is required to control the tissueshield movement of 0.14 inches. For rotary adjustment links, such asshown in FIGS. 37c, the rotary input range should be approximately 180°for the required shield movement of 0.14 inches.

As is shown in FIG. 37a, in the case of a gearing mechanism controllingthe tissue shield, the adjustment link movement is linear. This movementis geared down to advance the tissue shield at a reduced rate. If thecontrolling mechanism is in the form of a screw, the nut 198, as shownin

FIG. 37b, is rotated while being prevented from advancing. The tissueshield cannot rotate. Consequently, it advances as nut 198 is rotated.

If the controlling mechanism is a rotary cam, such as 200 in FIG. 37c,the tissue shield is advanced by a close fitting rotary cam within a camslot 202. The cam is rotated about a center eccentric to its own. Thismechanism is sometimes referred to as a "scotch yoke". Finally, if thecontrolling mechanism is a linear cam such as 204 in FIG. 37d, the fixedhousing 206 contains an inclined slot 208. The tissue shield contains asecond slot 210 at a small angle to slot 208. The adjustment link 196d,a slide which engages both slots, moves from position 1 to 4. As itmoves, the tissue shield is appropriately advanced.

In another preferred embodiment for a variable tissue approximationtechnique for this invention, since the upper anvil location determinesthe place where the staple is formed, by making the upper anvil locationvariable, as is shown in FIGS. 39a and b, case 12 acts to shield thetissue varying the degree of tissue approximation. In this method ofadjusting the upper anvil location, an inclined cam technique ispreferable wherein a slot 212a on case 12 and another slot 212b on upperanvil 150 are coupled via a slide button 214 (See FIGS. 40a and b). Theshallow angle insures that the upper anvil does not move during stapleformation through the mechanism of frictional lock-up. As the button isslid from side to side, upper anvil 150 is cammed in and out to therebyvary the distance between the upper anvil and the staple points.

As shown herein, all functions of the device (turning, transporting,forming, stripping and loading) are accomplished as part of thecontinuous mechanical action This invention allows the manufacturing ofa surgical stapler wherein the stack of staples 52 is configured in atypical orientation as those of a conventional paper stapler. Thepresent invention also includes a means for transporting, turning,stripping and forming the leading staple so that the staple may bedirected perpendicular to the tissue to be closed and that stapler maybe used by the surgeon at approximately 45° to the surface of the skin.

In addition, the present invention provides a surgical stapler in whichthe staple is advanced so that rotation occurs within the housing, thestaple is set at the end of the forward stroke and the staple isreleased on the return stroke of the former. In addition, this surgicalstapler provides for a varying mechanical advantage to accommodate thestaple advance at a reasonable hand force level and also provides forvarying the amount of tissue which is drawn up or approximated withinthe perimeter of the form staple.

To produce the proper movement pattern of parts for turning,transporting, forming, stripping, and loading of the staples, manydifferent mechanisms may be devised. However, the preferred embodimentsdisclosed herein are not only remarkably simple to manufacture and use,they are designed to be extremely inexpensive to produce, while stillmeeting all the objectives described in the earlier paragraphs.

While the preferred embodiments of the present invention have beendescribed, it should be understood that various changes, adaptations andmodifications may be made therein without departing from the spirit ofthe invention and the scope of the appended claims.

What is claimed is:
 1. A stapling device for use in ejecting a singlestaple to close an incision or wound comprising:a case including astaple discharge area; a cartridge assembly adapted to receive aplurality of staples in a generally stacked planar arrangement disposedwithin said case at a first plane; a pusher assembly engageable withsaid stack of staples and movable between a first rearward position anda second forward position to advance said stack of staples; controlmeans for turning a single staple around an axis generally normal tosaid stack of staples to form a turned staple, wherein said turnedstaple is at a second plane other than the first plane of the stack ofstaples, wherein said control means further comprises:a first anvilhaving a staple transport surface and a staple forming surface extendinggenerally upwardly form said staple transport surface; a second anvilpositioned generally above said first anvil; a former including a pairof arms which impinge upon the legs of the staple and a pair ofprojections extending upwardly therefrom, said former being displaceablebetween a start position wherein the legs of the staple are generallyperpendicular to the horizontal axis of the former and the crossarm ofthe staple being reliably retained within an opening defined by thestaple transport surface and a step extending upwardly from said pusherassembly, and a first intermediate forward position wherein said legs ofsaid former impinge upon the arms of the staple forcing the staple torotate generally perpendicular to the stack of staples; means for movingsaid turned staple a predetermined distance within the device; formingmeans for forming the staple into a closed gripping configuration;stripping means for disengaging the stale to be ejected from the device;and loading means for loading a single staple within said stack ofstaples into a position to be turned.
 2. The stapling device of claim 1wherein said moving means further includes said projections moving saidturned staple and said former from said first intermediate forwardposition to a second intermediate forward position wherein movement ofthe staple ceases when the lower anvil abuts a forward stop.
 3. Thestapling device of claim 1 wherein said second anvil includes a lipdepending downwardly therefrom.
 4. The stapling device of claim 3wherein said moving means further includes said projections moving saidturned staple and said former from said first intermediate forwardposition to a second intermediate forward position wherein movement ofthe staple ceases when said first anvil abuts against said downwardlydepending lip of said upper anvil.
 5. The stapling device of claim 4wherein said forming means further includes means for moving said formerfrom said second intermediate forward position to a third intermediateforward position wherein the pair of projections of said former engagesaid crossarm of said staple for forming said staple in a closedgripping configuration around said staple forming surface of said firstanvil.
 6. The stapling device of claim 5 wherein the width of the lip ofsaid second anvil is less than the width of said staple forming surfaceof said first anvil such that the staple does not bind onto said lipwhen said former retracts.
 7. The stapling device of claim 5 whereinsaid former includes a cam extending downwardly therefrom and a means torestrain said formed staple; and said first anvil includes a camfollower surface projecting upwardly therefrom.
 8. The stapling deviceaccording to claim 7 wherein said former is moved from said thirdintermediate forward position to a final forward position wherein saidcam engages said cam follower surface to thereby flex downwardly saidfirst anvil, and a setting button extending upwardly from said formercontacts the staple and pushes the staple into abutting engagement withsaid lip of said upper anvil.
 9. The stapling device according to claim8 wherein said setting button pushes the staple into abutting engagementwith said lip of said second anvil thereby alleviating bowing of thecrossarm of the staple.
 10. The stapling device according to claim 8wherein in the former final forward position the staple is retainedwithin the stapling device by said second anvil and said means torestrain said formed staple of the former.
 11. A stapling device for usein ejecting a single staple to close an incision or wound comprising:acase having a bottom and a top side and a staple discharge area, acartridge assembly adapted to receive a plurality of staples in the formof a stack in a generally planar arrangement disposed within said caseat a first plane, a pusher assembly engageable with said stack ofstaples and movable between a first rearward position and a secondforward position to advance said stack of staples, control means forturning a single staple of the stack of staples from a first position toa second position at a significant angle to said first position to forma turned surface, wherein said turned staple is positioned at a secondplane other than the first plane of the stack of staples, wherein saidcontrol means comprises,a first anvil having a staple transport surfaceupon which said plurality of staples are transported and a stapleforming surface extending generally upwardly form said staple transportsurface; a second anvil positioned generally above said first anvil; anda former engageable with the legs of said staple to be ejected andcooperable with means to restrain said staple and displaceable between afirst position wherein said staple is in its initial plane oforientation and a first intermediate forward position wherein saidstaple is rotated to it plane of ejection; transporting means for movinga single staple to be ejected within the device such that the staple canbe discharged from the device at a significant angle less then 90° fromthe incision or wound, forming means for forming the staple into aclosed gripping configuration, and stripping means for disengaging thestaple to be ejected form said device and to eject the fully formedstaple.
 12. The stapling device according to claim 11 wherein saidformer includes a pair of arms which impinge upon the legs of the stapleto rotate the staple to its plane of ejection when said former isadvanced to tis first intermediate forward position, said former alsoincluding a plurality of projections extending upwardly therefrom. 13.The stapling device according to claim 12 wherein said control meansrotates the staple generally normal to the stack of staples.
 14. Thestapling device of claim 12 wherein said second anvil includes a lipdepending downwardly therefrom.
 15. The stapling device of claim 14wherein the transportation means further includes said projectionsmoving the turned staple and the former from said first intermediateforward position to a second intermediate forward position wherein thefirst anvil abuts against the downwardly depending lip of said secondanvil
 16. The stapling device of claim 15 wherein the forming meansfurther includes means for moving said former from the secondintermediate forward position to a third intermediate forward positionwherein the pair of projections of the former engage said cross-arm ofsaid staple for forming said staple in a closed gripping configurationaround said staple forming surface of said first anvil.
 17. The staplingdevice of claim 16 wherein the width of lip of said second anvil is lessthan the width of said staple forming surface of said first anvil suchthat the staple does not bind onto said lip when said former retracts18. The stapling device according to claim 17 wherein said formerincludes a cam extending downwardly therefrom and a means to restrainsaid formed staple; and said first anvil includes a cam follower surfaceprojecting upwardly therefrom.
 19. The stapling device according toclaim 18 wherein said former is moved from said third intermediateforward position to a final forward position wherein said means forengaging said cam follower engages said cam follower to thereby flexdownwardly said first anvil, and a setting button extending upwardlyfrom said former contacts the staple and pushes the staple into abuttingengagement with said lip of said second anvil.
 20. The stapling deviceaccording to claim 19 wherein in the former final forward position thesetting button pushes the staple into abutting engagement with said lipof said second anvil.
 21. The stapling device according to claim 19wherein in the former final forward position the staple is retainedwithin the stapling device by said second anvil and said means torestrain said formed staple of the former.